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SPECIFICATION FOR SUPPLY, INSTALLATION AND COMMISSIONING OF

CNC 3-D COORDINATE MEASURING MACHINE

WITH ACCESSORIES

TECHNICAL SPECIFICATION NO: TS/ED/2006/34

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Research Designs and Standards Organisation Manak Nagar, Lucknow 226 011, India

1 PREAMBLE
1.1. Research, Designs & Standards Organisation (RDSO), Ministry of Railways, Govt. of India is situated at Manak Nagar, Lucknow, India. This Organisation is engaged in research, design & standardisation of works in various railway disciplines. Engine Development Directorate works for testing & development of diesel engines used on Indian Railways. 1.2. The 3-D Coordinating Measuring Machine will be used primarily for prototype development and inspection of various diesel engine components with the object for uprating the performance of medium speed, turbocharged ALCO/DLW built 16-Cylinder, 12-Cylinder, 6-Cylinder Diesel Engines & GM-EMD 16Cylinder Diesel Engine installed at Engine Development Directorate. 1.3. The machine should be capable to measure the following components accurately in manual as well as in auto modes through CNC Programme. The tenderer should demonstrate the measurement of the dimensions of following components. 1.3.1. 1.3.2. 1.3.3. 1.3.4. 1.3.5. 1.3.6. 1.3.7. Piston Connecting rod Cam shaft Cam shaft gear Cylinder Head Cylinder liner Push rods

The drawing of above components is at Annexure-II.

2 SCOPE OF SUPPLY
The offer given by the tenderer to supply, install and commission 3-D Coordinating Measuring Machine along with the software and its peripherals for multi-point and continuous measurement of sizes, form, position, features, 2D/3D and known/unknown contours shall include the cost of equipments detailed from para 2.1 to 2.11. However, the cost of all these items be indicated separately. Broad Details of Equipment Deliverables with quantity are given at Annexure-I. 2.1. CNC 3-D Coordinate Measuring Machine with continuous scanning probe head for self centering of probes, necessary probe kits, adapter plates, probe magazine and standard accessories should be offered having the features detailed in para-4 of specification. 2.2. Basic CNC Geometry Software module should be offered to complete all measuring tasks like sizes, form and position. The software should have the features specified in para-5 of specification.

2.3. A CNC Software module should be offered for measurement of 2D/3D and known/unknown contours of complex components. The software should have the features specified in para-6 of specification. 2.4. An industrial Computer Package System specifications detailed in para-7 of specification. should be offered having

2.5. Maintenance spares for two years for the systems. The list of recommended spares along with their cost should be given in detail. 2.6. All the tooling required for the operation and maintenance of the system. 2.7. Operation, software and maintenance premises/training center of the supplier. training at the manufacturers

2.8. Operation training at site after installation of machine covering each and every measurement function of the machine, usage of all software modules, trouble shooting, calibration and basic maintenance of the system. 2.9. Calibration certificates of the machine, wherever applicable, traceable to National/International Standards. 2.10.Two copies each (English version only) of the relevant operating manual, maintenance, service & calibration manual, trouble shooting guide and detailed electrical wiring diagram (Block & Schematic). 2.11.Installation and commissioning of the machine at Engine Development Directorate, RDSO either by firm engineers or by their agents, if any. Apart from above, the tenderer should offer the following modules as optional along with the offer. 2.12.A software module to export the IGES CAD model directly to 3D-CMM model for measurement and comparison between actual & design part to avoid errors in manual input of nominal data of design on 3D-CMM. 2.13.To supply, installation and commissioning of a suitable air filter and drier with a pressure regulating valve required to supply 6 to 10 bar, pre-filtered consumption of 30 liters/minutes, 60 Rh, 98% clean air for the operation of the machine. However, Engine Development Directorate will provide compressed air point near to the machine. 2.14.To supply, installation and commissioning of a suitable rotary table with necessary software module to interface with the machine for continuous scanning of the different components as mentioned in para-1.3. The documentary evidence should be enclosed with the offer to prove that the tenderer has already installed the rotary table also with the 3-D CMM at minimum five locations and are working satisfactorily.

3 GENERAL REQUIREMENTS
3.1. In the offer, the tenderer must indicate the ambient conditions/facilities/equipment to be provided by RDSO for installation and commissioning of the system. 3.2. The tenderer should supply foundation drawing. 3.3. The tenderer should supply foundation kit such as bolts, dampers and other necessary items required for installation of the machine. 3.4. For all the major bought out items/components, the essential details should be given in the offer. The details must include Name and address of original equipment manufacturer, model number, printed leaflet for the concerned model and other essential technical details. 3.5. The equipment shall be sturdy and reliable in operation and incorporate components that can withstand the hostile environmental conditions of the engines such as dust, water, fuel/lubricating oil, vibration, extreme temperatures and electrostatic interferences. 3.6. The electromagnetic compatibility of the equipment shall be at such level so as to minimize errors. 3.7. The system operation shall be unaffected by the vibration and shock under the normal operating conditions. 3.8. The supplier must have experience of minimum 05 years in the field of similar type machine installations and must have executed such type of projects in India/Abroad. 3.9. The tenderer must enclose along with the offer the documents establishing his past credentials. The copies of certificates for the last two years of successful installation, commissioning and working of the systems of similar specifications supplied by the tenderer in the past in India or abroad at minimum five locations, should be enclosed along with the offer. 3.10. The tenderer must have well organised after sales service backup in India. Sufficient number of trained personnel should be available in the above service centre. The details must be given in the offer. 3.11. The tenderer shall confirm that he will undertake Comprehensive AMC for at least 10 (ten) years period for the offered equipment. The tenderer shall submit a separate offer along with the main offer for comprehensive AMC of the equipment for a period of 03 years after the expiry of warranty period of equipment. 3.12. In addition, the tenderer must give para-wise remarks to all the clauses of specifications. Without these, the offer is likely to be summarily rejected.

Various design features incorporated in the offer to fulfil different technical and performance requirements be fully explained in the offer. 3.13. However, tenderer may propose minor deviations from these specifications along with full technical details and specifications in order to improve capabilities, giving details of suggested alternative design. The tenderer, in such an eventuality, shall clearly indicate details of deviations and reasons thereof.

4 CNC 3-D COORDINATE MEASURING MACHINE

A computer numerically controlled 3-dimensional Coordinate Measuring Machine with high performance continuous scanning probing system, complete in all respects should be offered having the following features: 4.1. Measuring range as given below: X-Axis = 700 mm (min) Y-Axis = 700 mm (min) Z-Axis = 600 mm (min) 4.2. Measuring Uncertainty independent of the position of the spindle as per EN ISO 10360-2: a) Volumetric Length-measuring error = 1.8 + L/300 m at 18 0C 22 0C b) Probing Error = 1.8 microns in all planes, viz XY, XZ and YZ

4.3. Scales: Reflected light system, photo elastic having a resolution of 0.2 m. The measuring scales should be less susceptible to dirt and contaminations. 4.4. Granite table should be of grade I as per ISO/DIN 876-1 provided with threaded insert for clamping of work piece, robust design with durable and secure surface. Ceramic guide way technology for rigidity and stability against temperature changes, moisture and other contaminants. 4.5. The control/operating panel should be standard, portable, with function keys and computer independent. Dual control joy sticks for easy and more precise remote control of 3-axis movement. Variable speed control in CNC modes. 4.6. The machine should have an integrated passive vibration damping system to with stand floor vibrations. 4.7. The machine should be capable of complete automatic measurement of precision components. It should be able to perform measurement of all

parameters on five faces of component from start to finish without operators intervention in between. 4.8. It should be possible to carry out the inspection without physical alignment of the work piece. 4.9. The machine should be capable of measurement in point to point as well as in continuous mode. 4.10.The machine should be capable of processing the measuring of all geometric parameters including nominal/actual comparison and evaluation of all form and position errors like flatness, straightness, roundness, cylindericity, parallelism etc. in accordance with ISO 1101 (MMC) simultaneously after the same measuring run. 4.11.For each individual job the machine should produce a printout detailing all actual dimensions as measured. Dimensions deviating from the laid out tolerances are to be indicated specifically, with the magnitude of deviations, including tolerance band utilization. 4.12.The machine should be specifically designed and engineered for carrying out high precision measurements of 3 dimensional coordinates in a single set up from all sides and at an angle in flat and box type components. 4.13.The machine should have air bearings in all axes. 4.14.Drive system movements should be motorized, all moving parts should slide on wear-proof guide to achieve minimum stick-slip ratio and long accuracy life. 4.15.Machine should be able to call almost all the important functions of the operating software from the panel. 4.16.Universal six-directional probe head with linear and torsionally rigid spring parallelogram, linear motors for measuring force generation with linear measuring system. The probe head should be suitable for measurements in following 3 modes in the same single probe configurations: 4.16.1. Single point measurements in static zero condition 4.16.2. Measurement with double flank contact in self-centering mode suitable for measurements of gears, racks, pinions, threads etc. 4.16.3. Continuous/uninterrupted scanning with built-in inductive measuring system capable to scan in any plane, curved and inclined surfaces. 4.17.Probe head should be suitable for active scanning and should have possibility to scan with all 3 axes free in the probe head or scan with individual axis/axes clamped.

4.18.Possibility of independent selection of probe axis locking and unlocking. 4.19.Minimum probe head deflection range for collision protection and continuously variable measuring force with direction selection. 4.20.Should have manual angular adjustments/clamping facility in making any probe configuration, so that any required angular positioning of the stylus/extensions can be made to suit any angular bore measurements. 4.21.Crank probe configuration should be possible to make and use with longer extensions up to 300 mm in all the planes. 4.22.Universal facility to build different probe configurations including angular positions should be possible, so that such probe configurations once build and calibrated can be used in manual probe changing or in automatic probe changing mode to avoid loss of time for intermittent recalibrations and to get optimum accuracy and repeatability instead of angular repositioning of the stylus with the help of indexable probe head so as to avoid errors due to angular and backlash of the indexed positions which gets magnified further when used with long extensions. 4.23.Should be able to carry probe tips up to 400 gm/300 mm extensions. The tip extensions, adaptors and probe body should be collision protected. Smallest diameter probe that can be used on the machine should be less than/equal to 1.0 mm. 4.24.Measuring force during data acquisition should be variable from 50 to 1000 mN

5 3-D GEOMETRY MEASURING APPLICATION SOFTWARE

A universal geometric measuring program should be offered for both manual and CNC operation of all measuring tasks like sizes, form and position of geometric elements, complicated elements with MMC provision. The software should have the following features: 5.1. Component misalignment compensation in plane and space. 5.2. Batch component position programming. 5.3. Form and position tolerance calculations and measurements according to DIN 7184/ISO R 1101. 5.4. Measurement of conic sections. 5.5. Auto recognition of standard geometrical elements.

5.6. CNC program and parameters for CNC runs are automatically generated while measurement. 5.7. Full feature graphic measurement and evaluation software with CAD core for all prismatic measurements. 5.8. Easy creation of measurement plans with object-oriented programming. 5.9. Easy to use procedure based on measurement schedule. 5.10.Graphic support including visualization of tasks and input data. 5.11.Few key operations and low susceptibility to errors due to automatic element identification and automatic probe route generation. 5.12.Variable presentations of results with simple integration of part related graphics. 5.13.Multimedia support for documenting the parts of clamping and probe configuration for the CNC start. 5.14.Intermediate results should be possible with graphical assistance in CAD window. 5.15.Printing of actual, nominal and deviation plots of measured data

6 3-D CONTOUR MEASURING APPLICATION SOFTWARE

A universal curve measuring program should be offered for both manual and CNC operation for measurement of 2D/3D and known/unknown contours of complex components. The software should have the following features: 6.1. It shall determine the actual contour of a part for form inspections of geometric elements as well as digitizing design models. 6.2. It shall have the capability to compare against the nominal and actual curves and give the difference in the two with error magnification about a tolerance band and deviation plots. 6.3. The software shall be suitable for all applications in curve and free-form metrology and reverse engineering. 6.4. Printing of actual, nominal and deviation plots of measured data.

7 SYSTEM COMPUTER PACKAGE

An industrial Computer Package System should be offered having industrial computer system, high end Intel based motherboard and processor with latest windows operating system. The computer system should act as interface between CNC 3-D Coordinate Measuring Machine and its controller for communication as well for software modules. The computer system with the following minimum configuration should be supplied with the machine: 7.1. Intel Based Mother Board with Intel 3 GHz Processor 7.2. 1 MB L2 cache Memory 7.3. 1 GB Main Memory 7.4. 21 TFT Digital Color Monitor 7.5. 256 MB Graphic Card 7.6. 2 nos. of 80 GB HDD 7.7. 3 1.44 MB FDD 7.8. DVD-CD/RW Drive 7.9. 104-Keys Cordless Key Board 7.10. Cordless Optical Mouse 7.11. Dual LAN Cards 7.12. Operating System: Windows NT/XP/2000 7.13. Antivirus Software with one-year license 7.14. A3-Size Laser Color Printer with network card 7.15. UPS System 7.16. Ergonomically Designed Desk for Machine Computer and Peripherals In addition to above, one Compact Data Processing and Analysis Machine with the following minimum configuration and carry case should be supplied with the CNC 3D coordinate measuring machine: 1. Processor Intel Pentium M 733 1.1 GHz with 2 MB L2 Cache 400 MHz FSB or higher

2. Motherboard 3. Memory 4. HDD 5. Display 6. Video controller 7. Modem 8. Wireless Connectivity 9. CD DVD Combo 10. Key Board 11. Expansion Port

Intel 855 PM Chipset or better 512 MB DDR SD RAM expandable up to 2 GB 60 GB, 5400 rpm or higher 26.4 cm TFT Active Matrix Display (1024x768 XGA Resolution) 32 MB DDR Video Memory dedicated Integrated 56 KBPS Modem (Fax/Data) and 10/100 Fast Ethernet. Integrated Wireless LAN 802.11b, Integrated Blue Tooth External 8X DVD-24X/8X CD R/RW Combo Drive and integrated stereo speaker Keyboard with Track Point 2 USB 2.0, Ethernet, External IEEE 1394, PCMCI Slot, Microphone, Headphone/Stereo and other standard features Microsoft Windows XP (Professional) Tablet PC Edition and Antivirus Software latest version with 60 days license 230V, 50Hz, 1 AC supply with rechargeable Battery pack comprising of Li-Ion Batteries suitable for approx 4 hours operation complete with Battery charger/adaptor

12. Operating system and other software pre installed 13. Power Supply

8 INSPECTION
The inspection of the machine will be carried out by RDSO representative at the manufacturing premises of the firm prior to the dispatch of the equipment. *************************************** *******************

Annexure-I

Broad Details of Equipment Deliverables

SN Details of Equipment CNC 3-D Coordinate Measuring Machine with continuous scanning probe head for self centering of probes, necessary probe kits, and adapter plates Software Module for measurement of Basic Geometry Software Module for measurement known/unknown contours Computer Package for Machine Maintenance Spares Operation & Maintenance Tooling Training Calibration Certificates Documentation of 2D/3D and Qty. Reqd 1 1 1 1 1 1 1 1 1 1 Ref. Para

1 2 3 4 5 6 7 8 9

2.1 & 4 2.2 & 5 2.3 & 6 2.4 & 7 2.5 2.6 2.7 & 2.8 2.9 2.10 2.11

10 Installation and Commissioning

Annexure-II

Annexure-III

Annexure-IV

Annexure-V

Annexure-VI

Annexure-VII

Annexure-VIII